Mechanic (Refrigeration and Air-Conditioning)

ITI Trade: Mechanic (Refrigeration and Air Conditioning)

Powered by NCVT (National Council for Vocational Training)

The ITI Mechanic (Refrigeration and Air Conditioning) trade is a highly specialized, job-oriented vocational course that provides in-depth technical training in the field of refrigeration and air conditioning (RAC). Powered and certified by the National Council for Vocational Training (NCVT), this program ensures that trainees acquire practical knowledge and theoretical understanding aligned with current industrial requirements. The course covers essential aspects of RAC systems ranging from domestic appliances like refrigerators and air conditioners to large-scale industrial cooling and air conditioning plants.

This trade is highly relevant for both government and private sector jobs, as well as self-employment opportunities. It empowers trainees to install, service, maintain, troubleshoot, and repair RAC equipment in a wide variety of environments, ensuring their services are always in demand. With the increasing use of cooling appliances in homes, offices, industries, and vehicles, the demand for skilled refrigeration and air conditioning mechanics is at an all-time high, both domestically and internationally.

The course has been meticulously designed to cater to the needs of Indian industries, while also preparing students to meet the global standards of the international RAC sector. Successful completion of this course opens up avenues in industrial HVAC installations, residential and commercial air conditioning systems, cold storage management, transport refrigeration, and automotive air conditioning systems, among others.

Course Overview and Objectives

The primary objective of the Mechanic (Refrigeration and Air Conditioning) trade is to develop a skilled workforce capable of handling complex tasks in the RAC industry. Students are taught how to:

• Identify and use RAC tools and equipment.
• Install, repair, and maintain domestic, commercial, and industrial refrigeration and air conditioning units.
• Work with various types of compressors, condensers, evaporators, and cooling towers.
• Perform leak testing, evacuation, gas charging, and recovery of refrigerants, including eco-friendly alternatives.
• Troubleshoot and repair electrical and electronic control systems of RAC appliances.
• Ensure compliance with energy efficiency and environmental regulations.
• Retrofit existing systems to use ozone-friendly refrigerants.

Scope of Employability

After completing the course, candidates have excellent employment opportunities in:

• Government sectors (Railways, Defense, Public Works Departments, etc.)
• Private RAC servicing companies
• Manufacturing industries producing refrigeration and air conditioning equipment
• Cold storage plants
• Large commercial establishments like malls, hotels, hospitals, and IT parks
• Automotive industries (Car air conditioning systems)
• International job markets in regions like the Middle East, Europe, Australia, and more

They can work in roles such as:

• Refrigeration Mechanic
• Air Conditioning Technician
• HVAC Installer
• Service Engineer
• Maintenance Technician
• Cold Storage Plant Operator
• Self-employed RAC Service Provider

Additionally, trainees can become entrepreneurs by opening their own refrigeration and air conditioning repair and servicing workshops.

Detailed Semester-wise Curriculum

The Mechanic (Refrigeration and Air Conditioning) course is typically divided into four semesters over two years, each focusing on specific skill sets to provide a comprehensive understanding of the trade.

Semester I: Basics and Foundation Skills

1. Safety Awareness: Understanding trade-related hazards and implementing safe working practices.
2. Fitting Jobs: Performing operations such as marking, sawing, filing, drilling, reaming, tapping, and dieing.
3. Sheet Metal Work: Producing components through marking, cutting, bending, riveting, and soldering.
4. Electrical Safety and Basic Circuits: Joining wires, measuring power, current, voltage, earth resistance; connecting single and three-phase motors with star and delta connections.
5. Electronic Components: Identifying and working with transistors, capacitors, diodes, amplifiers, integrated circuits (ICs), and soldering techniques.
6. Welding and Brazing: Performing gas welding, brazing, and soldering while ensuring safety.
7. RAC Tools and Systems: Identifying tools, components of RAC systems; cutting, flaring, swaging, and brazing copper tubes.
8. Refrigerator Installation and Testing: Testing components, leak testing, vacuuming, gas charging, wiring, and refrigerator installation.
9. Refrigerator Door Servicing: Performing door alignment, gasket fitting, and switch replacement.
10. Compressor Servicing: Testing compressor terminals, starting compressors (with and without relays), flushing, leak testing, replacing capillaries and filter driers, evacuation, and gas charging.
11. Frost Free Refrigerator: Checking components, wiring, air distribution, leak detection, evacuation, and gas charging.

Semester II: Intermediate RAC Techniques

12. Hermetic Compressor: Dismantling, repairing, assembling hermetic compressors, and testing their performance.
13. Compressor Terminals and Motors: Identifying terminals, measuring current, voltage, wattage, and using DOL starters.
14. Hermetic Compressor Selection: Selecting compressors for appliances, understanding starting methods, testing controls, and safety cutouts.
15. Inverter AC Control Systems: Identifying and wiring control systems in inverter ACs.
16. Condenser Servicing: Cleaning and descaling internal and external condensers.
17. Refrigerant Controls: Fitting and adjusting driers, filters, and refrigerant flow controls.
18. Evaporator Servicing: Servicing evaporators in different applications.
19. Refrigerant Recovery and Recycling: Handling refrigerants, recovering and recycling CFC/HFC gases, and using eco-friendly alternatives.
20. Retrofit Systems: Retrofitting CFC/HFC machines to ozone-friendly refrigerants.
21. Thermal Insulation: Packing insulation to prevent cooling leaks.
22. Window AC Installation: Installing and testing electrical and electronic components of window ACs, diagnosing faults, and implementing remedial measures.
23. Split AC Servicing: Installing, wiring, diagnosing, and servicing split AC systems.
24. Car AC Servicing: Diagnosing faults, servicing, and repairing car air conditioning systems.

Semester III: Advanced Commercial and Industrial Systems

25. Commercial Compressor Servicing: Dismantling, checking, replacing parts, checking lubrication, assembling, and testing compressors.
26. Water Cooled Condensers: Servicing various types of water-cooled condensers.
27. Cooling Towers: Performing maintenance and performance tests on cooling towers.
28. Water Treatment Plants: Servicing, backwashing, and regenerating water treatment plants.
29. Expansion Valve Fitting: Installing and adjusting valves to control refrigerant flow.
30. Evaporator and Chiller Servicing: Maintaining evaporators and chillers.
31. Water Cooler and Dispenser: Servicing and retrofitting water coolers and dispensers.
32. Visible and Bottle Cooler: Servicing and testing performance of coolers.
33. Deep Freezer Servicing: Testing and maintaining deep freezers.
34. Ice Cube Machine: Installing, servicing, repairing, charging gas, and performance testing.
35. Ice Candy Plant: Repairing, servicing, and retrofitting ice candy plants.
36. Ice Plant Servicing: Servicing ice plants and evaporative condensers.
37. Cold Storage: Performing preventive maintenance on walk-in coolers and cold storage units.

Semester IV: Centralized Air Conditioning and Advanced Systems

38. Psychrometric Properties: Studying psychrometric charts, measuring DBT, WBT, RH, and airflow.
39. Motors and Blowers: Servicing motors and blowers in AC systems.
40. Ducting and Insulation: Constructing, installing, and insulating air ducts.
41. Air Filters: Servicing and maintaining different types of filters.
42. Package AC (Air Cooled): Servicing, diagnosing, and repairing packaged AC units with air-cooled condensers.
43. Package AC (Water Cooled): Servicing and diagnosing packaged AC systems with water-cooled condensers.
44. Central AC Components: Identifying and wiring components, servicing AHUs, dampers, condensers, and cooling towers.
45. Pump Down and Charging: Performing system pump down, oil top-up, gas charging, and temperature/pressure checks.
46. DX Systems: Wiring, leak testing, evacuating, charging, and troubleshooting DX systems.
47. VRF/VRV Systems: Identifying, checking, and servicing VRF/VRV air conditioning systems.
48. Chiller Systems: Servicing indirect chillers, piping, dampers, FCUs, and water control valves.

Generic Learning Outcomes

• Troubleshooting central AC plants (DX and indirect systems).
• Servicing mobile ACs (including wiring, magnetic clutch testing, gas charging).
• Performing preventive maintenance, maintaining logbooks.
• Adhering to safety practices and environmental regulations.
• Applying basic math and science principles to electrical and mechanical tasks.
• Reading and interpreting engineering drawings.
• Measuring component dimensions accurately.
• Understanding productivity, quality, and labor laws.
• Promoting energy conservation and reducing pollution.
• Developing entrepreneurial skills and personal finance management.
• Planning and executing occupational tasks efficiently.

Conclusion

The ITI Mechanic (Refrigeration and Air Conditioning) trade offers comprehensive training to develop highly skilled professionals in the RAC sector. Graduates of this program are industry-ready and have access to multiple career paths in government organizations, private enterprises, and international job markets. With increasing demand for energy-efficient cooling solutions, this trade not only ensures gainful employment but also empowers candidates to become successful entrepreneurs in the rapidly growing refrigeration and air conditioning industry.